HIGH SPEED RAIL ROLLING

STOCK TECHNOLOGY

Silabhadra Das
Professor(IRIMEE)
HANDSHAKE WORTH
Rs 1000000000000
 OBJECTIVE
By the end of this lecture, participants will be able to-
The design requirements of a High speed rail rolling
Understand
stock

the difference between Concentrated Power train and

Explain
Distributed Power train

Describe briefly the history of HSR

Aspects of high speed rolling stock being incorporated

Explain
in MAHSR
BULLET TRAIN
 High Speed Rail (WHAT)

• Operational speed greater than 200 Kilometer per

hour on existing track
• Operational speed greater than 250 Kilometer per
hour on new track
• Significantly faster than traditional railway trains
• E.g.- Bullet Train (Japan)
- ICE (Germany)
- TGV (France)
- CRH (China)
VANDE BHARAT EXPRESS
 SEMI HIGH-SPEED RAIL
Operational speed between 160 Kilometer
per hour to 200 kilometer per hour

e.g. Vande Bharat Express, Gatiman

Express
 HOW

Concentrated Power train

Locomotive Coach Coach Coach Coach Coach Coach Coach Coach Coach

Distributed Power train

Motor coach Coach Coach Motor coach Coach Coach Motor coach Coach Coach
History of HSR (WHEN & WHERE)
1964 - JAPAN – SHINKANSEN

(210 KMPH)
Distributed Power EMU trainset with 6 motor coaches
1983-FRANCE
TGV -300 Kmph

Developed by ALSTOM

Concentrated Power
1991-Germany-
ICE1-280Kmph
Developed by
Siemens
Concentrated
power
WHICH COUNTRY HAS THE LARGEST HIGH-SPEED
RAIL NETWORK TODAY ?
2008
2017
 HSR in CHINA
• 1997 – China launched large scale speed up campaign
• 1999 – China star EMU was developed indigineously (Vmax = 250 Kmph). Was a
commercial failure
• January, 2004 – Chinese government identified 4 North-South and 4 East-West
corridors for High speed rail
• October, 2004 – Chinese Railway ordered 60 sets of CRH 2A rolling stock from
Kawasaki, 40 sets of CRH5A from Alstom, 60 sets of CRH1A from Bombardier. All
had to adapt their HSR train-sets to China's own common standard and assemble
units through local joint ventures (JV) or cooperate with Chinese manufacturers.
• 2008 – First commercial High speed rail trains were operated.
• 2013 – Independent innovation started. China standard EMUs with individual
Intellectual Property Rights
 WHY HSR?
• 1,600 million passengers per year carried
by high speed trains in the world
• 80% modal split obtained by high speed
trains in relation to air transport when
travel time by train is less than 2.5 hours.
• HSR stations are important nodal points in
city centres and they serve wider social
functions, by offering accessibility to a
comprehensive and wide range of services,
such as shopping facilities
 WHY HSR?

HSR provides city centre

to centre connectivity.
Lesser Door to Door
travel time.
 WHY HSR ?

• Energy efficient
• Lesser carbon
footprint
 Rolling stock requirement
• Self propelled, fixed composition and bi-directional
• High level of technology
• Limited axle load (11 to 17 tons for 300 km/h)
• High traction power (approx. 11 to 24kW per ton)
• Power electronic equipment: GTO, IGBT based Control circuits
• Computer network. Automatic diagnostic system
• Optimised aerodynamic shape
• In-cab signalling system/s
• Several complementary braking systems
• High level of RAMS (Reliability, Availability, Maintainability and Safety)
• Airtight structure
Wheel
• Flatter tread, Wheel conicity should be 1:40, 1:60 or 1:80
SUSPENSION
AERODYNAMIC BODY DESIGN
Carbody
Tilting
 MAHSR ROLLING STOCK
E5 series Shinkansen, Top speed – 320 kmph
General Overview
TRAIN OPERATION PLAN
Year Start of After 10 Years After 20 Years After 30 Years
Operation (SOO)
Train Configuration 10 10/16 16 16
Number of Rakes 24 24 +11 44 71
Number of Train Trip (per day/one-direction) 35 51 64 105
Train Capacity 750 750/1250 1250 1250
Traffic Volume (day/one direction) 17,900 31,700 56,800 92,900
Peak Hour: 3 4 6 8
Off peak: 2 3 3 6
▪ Operational Control Centre: Sabarmati & Maintenance Depot/Workshop (Rolling Stock): Thane, Sabarmati & Surat
▪ Train Acceleration: 0 to 320 Km/h in 310 s (distance - 18 Km)
▪ Braking: Service brake: 320 to 0 Km/h in 167s (distance - 8.5 Km)
▪ Power failure detection brake: 320 to 0 Km/h in 78s (distance - 3.87 Km)
▪ Classes of coach: 3 types (Standard, Business, Grand Class)
▪ Tentative Fare: Standard class 1.5 times of AC-I (about INR 3000)
▪ Annual Energy requirements (Trains, Stations etc): 1100 million unit
MAHSR Rolling Stock
Car No.1 Car No.2 Car No.3 Car No.4
Motor Car
Trailer Car Motor Car Motor Car
with Pantograph
(30) (100) (85) (100)

Car No.5 Car No.6 Car No.7 Car No.8

Motor Car
Motor Car Motor Car Motor Car
with Pantograph
(59) (100) (85) (100)

Car No.9 Car No.10

Motor Car Trailer Car

(55) (15)
Business class Grand /First class

• 10 car train (8-Motorized & 2-Trailer) 729 Seats - Start of Operation

• 16 car train (14-Motorised & 2-Trailer) 1250 Seats – After 10 years
Achieving High Speed
Aerodynamic Design
For high speeds, air drag is to be minimized.
Aerodynamically designed Car body with long nose to reduce drag

When high speed train exits a tunnel, a blasting sound is generated due to micro pressure waves. To reduce this
micro pressure, the front car is designed with a nose section.
Achieving High Speed
Reducing Air Drag

Fairings fitted all around

the gaps between cars

Side and Bottom covers for Bogies

and other underframe mounted
equipment
Passenger Comfort
Avoiding Ear Pressure in tunnels Cross section area = 10.8m2

▪ The car body is pressurized to avoid

discomfort to passengers due to drop in
pressure inside the passenger cabin in tunnel.

▪ To achieve this complete car body is made air

tight and a pressure inside the car is kept
above the atmospheric pressure. End body structure

Roof structure

Side structure

End part of Central part of carbody End part of

carbody carbody

Double skin hollow Aluminum underframe

extrusions with truss section
Passenger Comfort
Noise Mitigation

Bogie covers Fairing (Smooth covers)

Sound-absorbing construction Pantograph noise insulation panel
between cars
Passenger Comfort
Noise Mitigation
Side view
of the Car

Bogie portion Main transformer Bogie portion

Floor board
arrangement

Sound insulation floor board, Al Sound insulation floor board, Al

honecomb+Carbon Steel, steel+glass wool, honecomb+Carbon Steel, steel+glass wool,
Al Floor
soundboard
insulation baord+foamed
and floor resin
covering material Aluminium honeycomb
Floor board panel floor
and floor covering board
material Floor board insulation
Al sound and floor covering material resin
baord+foamed

Air tight floor(double skin) Air tight floor(standard) of Al Air tight floor(double skin)
Air duct for air conditioner

Sound proofing in the floor -- Inside noise < 70 dB (A)

Passenger Comfort
Special Lurch Control System
Intelligent control system that detects car body swaying and then reduces lateral vibrations.
Passenger Comfort
Ergonomically designed interiors
▪ Soft indirect lighting
▪ Seat leg rests operate in conjunction
with seat tilting.
▪ Seatback has an improved shape
▪ Reading lamp is installed in a seatback
upper corner.
Seat pitch : 1300mm,
width : 520mm
Grand/First class
▪ All seats have adjustable headrests
▪ When a seat is reclined, a seat
sliding mechanism operates in
tandem.
▪ Flip-up type Armrests (middle ones)
Passenger Comfort
Modernised toilets
Men’s urinal Women’s toilet Wheelchair accessible toilet

Men &Women’s
toilet

Women’s washroom Men and Women’s washroom Wheelchair accessible washroom

Passenger Comfort
Passenger Interface
▪ Voice communication system - Public address (PA) system;
Automatic announcement system; Emergency call equipment;
Wired / Wireless interphone (for crew).
▪ Staff rooms
▪ Refrigerator-freezer, hot-case, boiling water facility
and tea and coffee maker, hand towel warmer (Business
class)
▪ Space for On-board sellers

▪ English, Hindi, Gujarati and Marathi

▪ Train name and number
LCD type Passenger information display
▪ Current station, next stopping station and destination
▪ Schedule and expected time to reach next stop and
destination stations
▪ Information in emergency situations
▪ Text news
▪ Door-opening side
▪ Speed
Passenger Comfort
Facilities for the differently abled
Passenger Comfort
Multi-purpose room - Folding bed, baggage rack, mirror, etc. especially for sick persons or child feeding women.
Passenger Comfort
Emergency Intercom System
Security
Automatic Seat Rotation & Cabin Cleaning
Various Maintenance Schedules
Downtime for
Schedule Periodicity of schedules Main Items Attended
Schedule
Functional check of brake system, propulsion system, air-conditioners, pneumatic devices through S-TIMS;
Daily Inspection 48 hours 2 hrs. Check of bogies, wheels, pantographs, doors, interior equipment, toilets / washrooms, public address devices,
headlights, taillights, wipers; Consumables, light repairs

Regular Inspection 30,000 km or 30 days 8 hrs. All items of DI; Check of underfloor equipment; UST of axles
Bogie components (Bogie frame, Wheelset, Damper, WN Coupling, Axle Spring, Axle box, Axle bearing,
5 day
Bogie Inspection 600,000 km or 18 months Traction motor) are disassembled, inspected and re-assembled; Final inspection after bogie assembling; Test
run in depot and on main line
Uncoupling of cars of trainset; Disassembling of bogies; Disassembling of roof, underfloor, and interior
equipment, Inspection, repair and overhaul of equipment (almost all major equipment are inspected, repaired
General Inspection 1,200,000 km or 36 and overhauled – Pantograph, Tight lock coupler, Seats, Doors, Toilet WC, Master controller, Brake controller,
20 days
months Traction converter, Blower, APU, Battery, S-TIMS unit, Air-conditioner, Ventilation equipment, Waste & Water
tanks, Compressor); Painting; Air tightness of car body and wiring continuity test; Exchange of bogies;
Coupling of cars into train set; Final inspection, Test run in depot and on the main line
Based on noise/ vibration,
Wheel re-profiling 2 days As per requirement, Without de-coupling the trainset
wheel profile data
ATC Characteristics
90 days 8 hrs.
Inspection

a. 6 months a. Train radio function check

Train Radio Inspection 8 hrs.
b. 1 year b. Measurement of radio output power and radio frequency

As per nature
Un-scheduled repair Whenever necessary As per requirement, Without de-coupling the trainset
of repairs
General Inspection Train
➢ To ensure safety for the high speedrailway
operation
▪ Periodic inspection of the
track, S&T and electrical
facilities

▪ Accurate measurement during running

➢ Manufactured year; 2001, Design basis; E3

Shinkansen (1997)

▪ Maximum speed: 275 km/h

▪ Train formation; 5M1T; 5 motor cars

and 1 trailer car
General Inspection Train for MAHSR

Basic Concept

➢ Measuring/inspection equipment;

▪ based on the East-i.

▪ proven technology.

➢ Carbody and sub systems;

▪ based on the commercial
Train Set for MAHSR Design basis; E5
Maximum speed: 320 km/h
Train formation: 4M2T; 4 motor cars and 2 trailer car
Daily Inspection
Check function in cabin
(Brake, Propulsion
system, Air- Check Pantographs
conditioning, etc.) / check contact strips

Within 48 hours

Check Bogies Check Rest

and Wheels rooms
/ check
Brake linings

Check Doors
Regular Inspection
Check Doors Inspection of Pantographs
/ Replacement of contact strips

Check function in cabin,

(operation function, etc. ) Check cabin and interior
Within 30,000 km
or 30 days

Ultrasonic flaw Check

inspection for hollow Check Rest
Inspection of Bogies equipment
axle rooms
and Wheels
/ Replacement of
Brake linings

Clean or exchange
air filter
Bogie Inspection

Within 600,000
Bogies are exchanged Bogie components are disassembled,
km or 18
with spare bogies inspected and assembled
months
General Inspection
Almost all equipment are inspected and repaired

Within Disassemble Assemble

1,200,000 km
or 36 months

Disassemble & Inspected

Body Paint
Depot Machinery – A Summary
Type of Machine D-2 D-1 Some Examples
Tester 63 02 Bogie Running Test Machine, ATC Tester, Oil Damper Tester
Data reader 15 07 Data Management terminal, DS-ATC data reader, Other Data Readers
Measurement 17 04 Wheel-axle Ultrasonic Flaw Detector, Thrust Clearance Measurement Machine

Oil/Grease filling 05 00 Bearing Oil Filling Machine, TM Grease Filling Machine

Painting 27 00 Automatic Car body Painting Machine, Automatic Polishing Machine

Special Purpose 63 13 Wheel Lathe, Wheel-axle Ultrasonic Flaw Detector, Bogie Exchange Lifting Machine

Assembly / Disassembly 25 00 Wheel Fitting Press, Bogie Assembly Machine

Bogie Washing Machine, Gear Box / Axle Box Flushing Machine,
Cleaning/Drying 59 04
Automatic Car body Washing Machine Surat Depot
Cranes 12 02 Overhead Traveling Crane, Balancing Crane, Jib Crane ▪ Roof Safety Step;
Compressor 10 02 Air Compressor (High), Air Compressor (Low) ▪ Door Locking Device
Heaters 06 00 Bearing Induction Heater, WN Gear Coupling Induction Heater for Roof Deck;
▪ Underfloor Wheel
Material handing 13 01 Traverser, Underfloor Equipment Lifter, Forklift, Battery Car
Lathe
Storage 08 01 Wheel Set / Wheel Disc Storage Machine, TM Storage Machine ▪ Battery Pusher
Working Platform 07 01 Underfloor Inspection Vehicle, Lifting Deck Car, Working Deck ▪ Portable compressor
▪ Forklift.
General Purpose 21 04 Charging Machine, Punching Press, Arc Welding Device

Total 351 41 Summary Machines Sabarmati - 273 Different Types, 351 Specifications, 1023 Nos.
Some Key Machines for Safe Running at 320 km/h

➢ Automatic Carbody Washing Machine

➢ Bogie Running Test Machine

➢ Wheel-Axle Ultrasonic Flaw Detector

➢ Car Body Airtight Tester, etc.

➢ Automatic paint machine

Automatic Carbody Washing Machine
➢ Automatic Trainset washing
▪ Car body is sprayed with detergent and washed by
RO water (inbuilt RO system) .
▪ Distributed Washing Stations – Chemical & Water
▪ Speed 5 km/h or less
▪ Water Consumed : 340 L per car (ETP recycled
Water)
➢Machine Parameters / Configuration
▪ Chemical washing units (03 Nos.):
• Detergent spraying & brushing, 40 litres/minute
• Water spraying & brushing, 100 litres/minute

▪ Water washing units (01 Nos.):

• Washing Water spraying rate 440 litres/minute
• RO water spraying rate 280 litres/minute
▪ Control Room at 2 Locations
Bogie Running Test Machine
➢ Need - Malfunction of bogie leads to serious accident Temperature

➢ Test of the overhauled Bogie at 320 km/h under load Vibration

➢ Main Parameters
▪ Driving wheels (4 nos.) drive the Machine in both directions
▪ Testing room
▪ Measuring and operation room (Sound proof)
▪ Air is supplied to air suspension to simulate the car body load.
➢ Measurements
▪ Vibration and Temperature of axle bearing, traction
gear bearing, traction gear, and traction motor
▪ Air leakage from air suspension and piping
▪ Voltage and rotation speed of tachometer
generator
▪ Oil leakages
Wheel-Axle Ultrasonic Flaw Detector
➢ Higher loads and vibrations on the axle in high
speed running
➢ Detector detects flaws on hollow axle
➢ Main Parameters
▪ Automatic Flaw detection and whether axle is passed
or failed
▪ Memory - Approx. 80 Axles.
▪ Only 01 operator is required
▪ Automatic calibration with test axle
Car Body Airtight Tester
➢ Need - Car body is pressurized for passenger comfort

➢ Tester measures the airtightness of car body

➢ Main Parameters
▪ Tester supplies air into the car body through car end cover until
the test pressure (400 mm Aq (millimetre aqua or water column)
or 0.04 Kgf/cm2) is reached
▪ Measures the time taken for the pressure to reduce from 400 mm
Aq to 100 mm Aq or 0.01 Kgf/cm2 (should be 40 sec or more).
▪ Automatically judges whether the car body has passed / failed the
test
▪ Machine equipped with car end cover set
A Modern Paint Workshop
➢ Automatic Car Body Painting Machine
▪ Moving device - moves vertically and
longitudinally
▪ Robotic device – movement in all required
directions
▪ Painting is automatically stopped if ventilation
stops
➢ Booth with Ventilation
▪ Collects and exhausts paint mist and organic
solvents through filter and duct to the outdoors
▪ Ventilation and Exhaust System (3850 m3/min)
▪ Explosion proof lighting
 HSR operational speed greater than 200 Kmph

Distributed power trains desirable for HSR

Japan was the pioneer in the field of HSR

SUMMARY China is the current world leader in HSR

India will adopt HSR from Japan

HSR will boost the economy and will create

employement
THANK YOU